System and method for bimodal air control in a kettle-style grill

ABSTRACT

Exemplary embodiments of a system and method for bimodal air control in a kettle-style grill are configured to be detachably mounted to the exterior of a kettle-styled grill such as, but not limited to, a Weber® charcoal grill. When mounted to the kettle-styled grill, a plenum-like component directs air flows to the interior of the grill&#39;s kettle via the kettle&#39;s lower body damper holes. A manually adjustable intake damper in the plenum component allows, restricts, or prevents a drawn ambient air flow into the plenum component. Separately, a forced air flow generated by a fan may also be provided into the plenum component. Adjustment of the intake damper may also adjust damper blades inside the grill&#39;s kettle. Ash that falls out of the kettle&#39;s damper holes falls through the plenum component and is captured in an ash receptacle that is removably mounted to the plenum component.

BACKGROUND

The present invention relates to outdoor grilling and smoking solutionsand, more particularly, to a novel system for enabling bimodal aircontrol in a kettle-styled grill designed for use with charcoal.

Kettle-styled grills designed for use with a charcoal briquette fuelsource, such as a typical Weber® grill, are relatively inexpensive andubiquitous in the marketplace. As one of ordinary skill in the art ofkettle-styled grills would recognize, air flow is usually controlledmanually through lower dampers located in the bottom of the grill'skettle and, optionally, also through upper dampers located in the lid ofthe kettle. In addition to affecting air flow, the lower dampers mayalso be configured in a typical kettle-styled grill to agitate ash outof the kettle so that the ash may be collected in an ash can componentlocated beneath the kettle. With skill and knowledge, the manual dampers(lower and/or upper) of a typical kettle-styled grill may beperiodically adjusted and set by a user to control cooking temperatureand/or smoke retention within the grill.

The skill and knowledge required by a kettle grill user to effectivelymanipulate and control air flow with manual dampers has led the industryto introduce various forced-air “add on” solutions designed to alleviatea user's need for mastery of the manual dampers. The prior artsolutions, however, typically require that the kettle be modified with a“cut-out” and/or prevent a user from opting for manual damper control.

Therefore, there is a need in the art for a system and method that doesnot require modification of the grill's kettle and, additionally,enables a user to selectively alternate between a manual mode and anauto-mode for air control through the kettle. More specifically, thereis a need in the art for a bimodal air control system in a kettle-styledgrill.

SUMMARY

Exemplary embodiments of a system and method for bimodal air control ina kettle-style grill are disclosed. Certain embodiments are configuredto be detachably mounted to the exterior of a kettle-styled grill suchas, but not limited to, a Weber® charcoal grill. When mounted to thekettle-styled grill, a plenum-like component directs air flows to theinterior of the grill's kettle via the kettle's lower body damper holes.A manually adjustable intake damper in the plenum component allows,restricts, or prevents a drawn ambient air flow into the plenumcomponent. Separately, a forced air flow generated by a fan may also beprovided into the plenum component. Ash that falls out of the kettle'sdamper holes falls through the plenum component and is captured in anash receptacle that is removably mounted to the plenum component. Inthis way, embodiments of the solution do not require significant, ifany, modification to the kettle-styled grill in order for thekettle-styled grill to use the bimodal air control system. Embodimentsmay also include temperature loop control of the fan.

An exemplary embodiment of a system for bimodal air control in akettle-style grill having one or more damper holes in a lower portion ofits kettle comprises 1) one or more positionable damper bladesassociated with the one or more damper holes in the lower portion of thekettle, each damper blade operable to be positioned such that it opens,restricts or closes off its associated damper hole; 2) a damper plenumhaving an open top and an open bottom, the damper plenum comprising amanually adjustable intake damper and a forced-air input port, whereinthe manually adjustable intake damper is mechanically connected to theone or more positionable damper blades; 3) an ash receptacle componentremovably attached to the damper plenum; and 4) an air control unitcomprising a variable speed fan.

The air control unit may further comprise a temperature sensor inelectrical communication with an electronic controller configured tovary the speed of the fan. The electronic controller may be operable toapply a proportional-integral-derivative control algorithm and may alsobe configured to wirelessly communicate with a remote user device.

The damper plenum is configured to be mounted to the kettle-style grillsuch that the open top establishes a seal around an external area of thekettle that includes the one or more damper holes. The air control unitis attached to the damper plenum such that a forced air flow generatedby the fan enters the damper plenum through the forced-air input port.And a drawn ambient air flow enters the damper plenum through themanually adjustable intake damper when the manually adjustable intakedamper is in an open state.

Further to the exemplary embodiment, when the manually adjustable intakedamper is in an open state, the one or more positionable damper bladesare positioned in the kettle such that the one or more damper holes areclosed off. Similarly, when the manually adjustable intake damper is ina closed state, the one or more positionable damper blades arepositioned in the kettle such that the one or more damper holes arefully open. And, when the manually adjustable intake damper is in apartially open state, the one or more positionable damper blades arepositioned in the kettle such that the one or more damper holes arepartially restricted. Ash exiting the grill's kettle through the one ormore damper holes is captured in the ash receptacle which is below theplenum.

Another exemplary embodiment of a system for bimodal air control in akettle-style grill having one or more damper holes in a lower portion ofits kettle comprises: 1) means for opening, restricting or closing offeach of the one or more damper holes; 2) means for adjusting a drawnambient air flow between fully open, fully closed, and partially openstates; 3) means for adjusting a forced air flow; and 4) means forcapturing ash expelled from the kettle. The means for adjusting thedrawn ambient air flow operates simultaneously to adjust the means foropening, restricting or closing off each of the one or more damperholes. The drawn ambient air flow and the forced air flow both enter thekettle through the one or more damper holes.

When the means for adjusting the drawn ambient air flow between fullyopen, fully closed, and partially open states is in an open state, themeans for opening, restricting or closing off each of the one or moredamper holes operates to close off the one or more damper holes.Similarly, when the means for adjusting the drawn ambient air flowbetween fully open, fully closed, and partially open states is in aclosed state, the means for opening, restricting or closing off each ofthe one or more damper holes operates to open the one or more damperholes. And, when the means for adjusting the drawn ambient air flowbetween fully open, fully closed, and partially open states is in apartially open state, the means for opening, restricting or closing offeach of the one or more damper holes operates to restrict the one ormore damper holes.

The means for adjusting a forced air flow comprises a temperature sensorin electrical communication with an electronic controller configured tovary a speed of a fan. The electronic controller may be operable toapply a proportional-integral-derivative control algorithm and may beconfigured to wirelessly communicate with a remote user device.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an exemplary embodiment of a bimodal air controlsystem for kettle-styled grills according to the solution;

FIG. 2 is an exploded view of the exemplary embodiment shown in FIG. 1 ;

FIG. 3 illustrates the exemplary embodiment of FIG. 1 , shown mounted toa kettle-styled grill;

FIG. 4 is a sectioned view of the FIG. 3 illustration to illustrate theexemplary linkage between the novel system and the lower dampers of thekettle-styled grill;

FIG. 5 is a functional block diagram of the electrical componentscomprised within an exemplary embodiment of the solution for a bimodalair control system for kettle-styled grills; and

FIG. 6 is a flowchart illustrating an exemplary method for implementingbimodal air control in a kettle-styled grill using a bimodal air controlsystem according to the solution.

DETAILED DESCRIPTION

Various embodiments, aspects and features of the present inventionencompass a system and method for bimodal air control in a kettle-styledgrill (e.g., a Weber® grill designed for use with a briquette charcoalfuel). As one of ordinary skill in the art would understand andrecognize, kettle-styled grills are primarily designed for manualmanipulation of damper(s) to control an air flow through the kettle.

When a typical kettle-styled grill is used as intended, charcoal isplaced in the kettle of the grill and ignited. A cooking grate issuspended within the kettle over the top of the charcoal. Thermal energygenerated by the burning charcoal radiates upward toward the grate andcooks any food item placed thereon. To control temperature, rate of burnand smoke retention, kettle-styled charcoal grills usually rely on asomewhat crude, manual damper-type control. Some kettle-styled grillsincorporate the damper on the top of a lid that mates to and over thelower kettle. Other kettle-styled grills, however, such as what iscommonly known as a Weber® branded grill, incorporate a damper at thebottom of the kettle (often in addition to a damper on the lid of thekettle), thereby providing means for control of air directly to, andthrough, the burning charcoal.

As one of ordinary skill in the art would acknowledge, temperature, burnrate and smoke retention are all key parameters to be controlled whenusing a kettle-styled grill. And so, a user's experience and skill inleveraging the manual dampers may have a direct impact on the quality ofthe food being cooked. To improve control of the air flow in akettle-styled grill, incorporation of an electric fan and temperaturecontrol loop may be used in lieu of the manual dampers.

Advantageously, embodiments of the solution are configured to detachablyintegrate to a kettle-styled grill having lower dampers in the kettle,without requiring modification of the kettle, and provide a user with abimodal option to use the grill in a manual damper mode or in anauto-damper mode. When in the manual damper mode, the solution allowsthe user to rely on manual setting and manipulation of the lowerdampers, while in the auto-damper mode the user may rely on an electricfan to force air through the lower damper holes in response to atemperature control loop. As will be better understood from the attachedfigures and the following description, embodiments of the solution maybe integrated onto an existing kettle-styled grill without modifying thekettle (such as cutting a hole in the kettle) or rendering the lowerdampers inoperable for ash removal and manual damping.

Turning now to the figures, an exemplary embodiment of a bimodal aircontrol system 100 will be shown and described with collective referenceto the illustrations in FIGS. 1-5 . That is, each of the illustrationsin FIGS. 1-5 will be described simultaneously. FIG. 1 generallyillustrates an exemplary embodiment of a bimodal air control system 100for kettle-styled grills according to the solution, while FIG. 2illustrates an exploded view of same. FIGS. 3 and 4 illustrate theexemplary embodiment attached to a kettle-styled grill. FIG. 5 is afunctional block diagram of the electrical components comprised within acontrol system of an exemplary embodiment of the solution for a bimodalair control system for kettle-styled grills.

As should be apparent from the figures, the system 100 may be configuredfor mounting to the exterior of a kettle-styled charcoal grill. Thebimodal air control system 100 may be mated/juxtaposed to the kettle 210(see, for example, FIGS. 3 and 4 ) of the grill such that the system 100is positioned beneath and to the side of the kettle 210. The matingflanges 125 of the damper plenum 107 may form a tight seal with theunderside of the kettle.

The damper plenum 107 comprises a manually adjustable intake damper 115that, when partially open, provides for a restricted intake of a drawnambient air flow into the inner space of the damper plenum 107 (when thesystem 100 is in the manual damper mode) and, when fully closed,prevents inflow of ambient air into the damper plenum 107 whilesimultaneously preventing outflow of a forced air flow injected into theplenum 107 via a fan 105 (when the system is in the auto damper mode).Air flow into the plenum 107, whether from a drawn ambient air flow or aforced air flow generated by fan 105 (or a combination of both), mayexit the damper plenum 107 and enter the kettle 210 of the grill viaopen lower damper holes 215 (see FIG. 4 ).

To be clear, manipulation of the adjustable intake damper 115 positionvia handle 119 corresponds with manipulation of damper blade 212positions within the kettle 210 in order to open, restrict, or close offlower damper holes 215 in the kettle. The intake damper 115 may bemechanically connected to the damper blades 212 via connection 121 inorder for adjustment of the intake damper 115 to correspondingly causeadjustment of the damper blades 212. Generally, when intake damper 115is fully closed, the lower damper holes 215 may be fully open (due tothe position of damper blades 212) and the bimodal air control system100 may be in auto-damper mode such that the only air flow into thedamper plenum 107 (and subsequently into the kettle 210 via open lowerdamper holes 215) is a forced air flow attributable to electric fan 105.And, when the intake damper 115 is fully open, the lower damper holes215 may be fully closed (due to the position of damper blades 212) andthe bimodal air control system 100 may be in shutdown mode such that noair is allowed to flow into the kettle 210 from damper plenum 107. Whenthe intake damper 115 is partially open, the lower damper holes 215 mayalso be partially open (due to the position of damper blades 212) tomodulate air flow into the kettle 210 and the bimodal air control system100 may be in manual damper mode. When the system 100 is in manualdamper mode, a drawn ambient air flow may be pulled into the damperplenum 107 and, subsequently, into the kettle 210. Depending onembodiment of the solution, the fan 105 may provide a supplementalforced air flow into the damper plenum 107 when the system 100 is in amanual damper mode.

As one of ordinary skill in the art of kettle-styled grills wouldunderstand, manipulation of the damper blades 212 within the kettle mayagitate ash and cause the ash to exit the kettle through lower damperholes 215. The ash may fall gravitationally through the damper plenum107 and collect in ash can or ash receptacle 109. The ash can 109 may bereleasably connected to the lower portion of the damper plenum 107 via alatch 111 or other means. In this way, a user of the system 100 mayperiodically empty collected ash by simply disconnecting the ash can 109and without any need for disconnecting the damper plenum 107 and/or theentire system 100 from the grill.

Embodiments of the solution may leverage a controller 102 that includesa graphical user interface 101 or the like. The graphical user interface101 may be local (such as depicted in the figure illustrations) and/ormay be remotely displayed on a wirelessly connected user device. Thecontroller 102, along with a fan 105, may be comprised within an aircontrol unit defined by a housing 117 that is configured to mount on theoutside of the damper plenum 107 and the kettle 210. The controller 102may include a processor, memory component(s), wireless transceiver,power supply, etc., as would be understood by one of ordinary skill inthe art of electronic controllers. The controller 102 may have storedwithin its memory any one or more temperature control algorithms that,when executed by the processor, cause a speed adjustment to the fan 105.That is, the controller 102 may be configured to receive temperature setpoints dictated by the user or, depending on embodiment, a temperaturecontrol algorithm may predefine a temperature set point without userinput. The temperature setting informs the controller 102 in view of thetemperature sensor 123 signal to vary the speed of the fan. Thecontroller 102 may leverage a proportional-integral-derivative (“PID”)control algorithm, as would be understood by one of ordinary skill inthe art of process control. In this way, the controller 102 may adjustthe fan speed, and by extension the flow rate of a forced air flow intodamper plenum 107, in response to a temperature reading from temperaturesensor 123.

It is further envisioned that embodiments of the controller 102 may beconfigured to wirelessly communicate with a software application or thelike running on a remote user device such as, but not limited to, asmartphone or pad device. In such embodiments, the user interface 101may be partially comprised of a user interface on the remote userdevice. The user may leverage the remote user interface 101, and/or thelocal user interface 101 (as shown in the figures), to adjust selectionof the temperature control algorithm and/or monitor feedback data points(e.g., temperature, cooking time, alarms, etc.), as would be understoodby one of ordinary skill in the art.

The one or more temperature control algorithms may rely on inputs from atemperature sensor 123 that may be placed on the cooking grate orelsewhere inside the kettle 210. Depending on the particular embodiment,it is envisioned that the solution may leverage temperature sensorfeedback from multiple temperature sensors positioned in multiplelocations within and/or outside kettle 210. The temperature sensor(s)123 provides feedback to the controller 102 that, in turn, controls fanspeed. By controlling the fan speed, the controller 102 may cause acooking temperature to be maintained at a desired temperature settingsince a forced air flow into the damper plenum through input port 113will enter kettle 210 via lower damper holes 215 and affect cookingtemperature.

FIG. 6 is a flowchart illustrating an exemplary method 300 forimplementing bimodal air control in a kettle-styled grill using abimodal air control system according to the solution. Beginning withblock 305, the controller 102 may recognize or determine the position ofthe intake damper 115. In some embodiments, the controller 102 may relyon a user input to determine the intake damper 115 position while inother embodiments the controller 102 may be configured to receive aposition sensor input to determine intake damper 115 position.

Returning to the method 300, at decision block 310 the “yes” branch maybe followed if the intake damper 115 is fully open. With the intakedamper 115 fully open, the lower damper holes 215 in the kettle 210 maybe fully closed. And so, the method 300 may arrive at block 325 and setthe system 100 to shutdown mode. In shutdown mode, the controller 102may cease actuation of fan 105 or, alternatively, may continue to forceair through input port 113 into damper plenum 107 in order to improvethermal energy dissipation from kettle 210. The method 300 returns toblock 305 to monitor any changes in the position of intake damper 115.If at decision block 310 it is determined that the intake damper 115 isnot fully open, however, then the method 300 follows the “no” branch todecision block 315.

At decision block 315 the “yes” branch may be followed if the intakedamper 115 is fully closed. With the intake damper 115 fully closed, thelower damper holes 215 in the kettle 210 may be fully open. And so, themethod 300 may arrive at block 330 and set the system 100 to auto-dampermode. In auto-damper mode, the controller 102 may modulate the speed offan 105 based on an input from temperature sensor 123 and, in doing so,provide a forced air flow through input port 113 into damper plenum 107.A drawn ambient air flow into damper plenum 107 may be prevented byvirtue of the closed intake damper 115. The forced air flow may enterkettle 210 through the fully open damper holes 215 in order to affectcombustion and cooking temperature. The method 300 returns to block 305to monitor any changes in the position of intake damper 115. If atdecision block 315 it is determined that the intake damper 115 is notfully closed, however, then the method 300 follows the “no” branch todecision block 320.

At decision block 320 the “yes” branch may be followed if the intakedamper 115 is partially open. With the intake damper 115 partially open,the lower damper holes 215 in the kettle 210 may also be partially open.And so, the method 300 may arrive at block 335 and set the system 100 tomanual damper mode. In manual damper mode, the controller 102 maymodulate the speed of fan 105 based on an input from temperature sensor123 and, in doing so, provide a forced air flow through input port 113into damper plenum 107 that supplements a drawn air flow into damperplenum 107 from partially open intake damper 115. Alternatively, thecontroller 102 may shut off fan 105 such that the only air flow intodamper plenum 107 is a drawn air flow through the partially open intakedamper 115. The air flow may enter kettle 210 through the partially opendamper holes 215 in order to affect combustion and cooking temperature.The method 300 returns to block 305 to monitor any changes in theposition of intake damper 115. If at decision block 320 it is determinedthat the intake damper 115 is not partially open, however, then themethod 300 follows the “no” branch and the method 300 returns.

A system and method for bimodal air control in a kettle-style grillaccording to the solution has been described using detailed descriptionsof embodiments thereof that are provided by way of example and are notintended to limit the scope of the disclosure. The described embodimentscomprise different features, not all of which are required in allembodiments of a bimodal air control system according to the solution.Some embodiments of the solution utilize only some of the features orpossible combinations of the features. Variations of embodiments of thesolution that are described and embodiments of the solution comprisingdifferent combinations of features noted in the described embodimentswill occur to persons of the art.

It will be appreciated by persons skilled in the art that a systemand/or method for bimodal air control in a kettle-style grill accordingto the solution is not limited by what has been particularly shown anddescribed herein above. Rather, the scope of a system and/or method forbimodal air control in a kettle-style grill according to the solution isdefined by the claims that follow.

What is claimed is:
 1. A bimodal air control system, the systemcomprising: a plenum configured to removably mount over an undersidesurface of a kettle-styled grill, wherein the kettle-styled grillcomprises one or more damper holes in the underside surface and one ormore damper blades corresponding to the one or more damper holes; amanually adjustable intake damper located in a side surface of theplenum; a mechanical connection between the manually adjustable intakedamper and the one or more damper blades; an electric fan configured togenerate a positive air flow into the plenum; and an ash can removablymounted to the plenum and configured to capture ash exiting thekettle-styled grill through the one or more damper holes; wherein whenthe manually adjustable intake damper is in a fully closed state, theone or more damper blades are positioned such that the one or moredamper holes are in an open state; and wherein when the manuallyadjustable intake damper is in a partially open state, the one or moredamper blades are positioned such that the one or more damper holes arein a partially open state; and wherein when the manually adjustableintake damper is in a fully open state, the one or more damper bladesare positioned such that the one or more damper holes are in a closedstate.
 2. The bimodal air control system of claim 1, further comprisingan electronic controller in electrical communication with the electricfan.
 3. The bimodal air control system of claim 2, further comprising atemperature sensor in electrical communication with the electroniccontroller, wherein the electronic controller is configured to varyspeed of the electronic fan based on a signal input from the temperaturesensor.
 4. The bimodal air control system of claim 3, wherein theelectronic controller varies speed of the electronic fan according to aproportional-integral-derivative control algorithm.
 5. The bimodal aircontrol system of claim 2, wherein the electronic controller isconfigured to wirelessly communicate with a remote user device.
 6. Thebimodal air control system of claim 2, wherein the electronic controllercomprises a graphical user interface.
 7. A bimodal air control system,the system comprising: means for removably mounting a plenum over anunderside surface of a kettle-styled grill, wherein the kettle-styledgrill comprises one or more damper holes in the underside surface andone or more damper blades corresponding to the one or more damper holes;means for manually adjusting an intake damper located in a side surfaceof the plenum; means for simultaneously adjusting the one or more damperblades when adjusting the intake damper; electromechanical means forgenerating a positive air flow into the plenum; and means for capturingash exiting the kettle-styled grill through the one or more damper holesand falling through the plenum; wherein when the intake damper is in afully closed state, the one or more damper blades are positioned suchthat the one or more damper holes are in an open state; and wherein whenthe intake damper is in a partially open state, the one or more damperblades are positioned such that the one or more damper holes are in apartially open state; and wherein when the intake damper is in a fullyopen state, the one or more damper blades are positioned such that theone or more damper holes are in a closed state.
 8. The bimodal aircontrol system of claim 7, further comprising means for controlling theelectromechanical means for generating a positive air flow into theplenum.
 9. The bimodal air control system of claim 8, wherein the meansfor controlling is configured to vary speed of the electromechanicalmeans for generating a positive air flow into the plenum based on asignal input from a temperature sensor.
 10. The bimodal air controlsystem of claim 9, wherein the means for controlling varies speed of theelectromechanical means for generating a positive air flow into theplenum according to a proportional-integral-derivative controlalgorithm.
 11. The bimodal air control system of claim 8, wherein themeans for controlling is configured to wirelessly communicate with aremote user device.
 12. The bimodal air control system of claim 8,wherein the means for controlling comprises a graphical user interface.13. A method for bimodal air control in a kettle-styled grill, themethod comprising: mounting a plenum over an underside surface of akettle-styled grill, wherein the plenum comprises an adjustable intakedamper and the kettle-styled grill comprises one or more damper holes inthe underside surface and one or more damper blades corresponding to theone or more damper holes; removably mounting an ash to the plenum forcapturing ash exiting the kettle-styled grill through the one or moredamper holes; providing a mechanical connection between the manuallyadjustable intake damper and the one or more damper blades; configuringan electric fan to generate a positive air flow into the plenum;manually adjusting the intake damper, wherein: when the intake damper isin a fully closed state, the one or more damper blades are positionedsuch that the one or more damper holes are in an open state; and whenthe manually adjustable intake damper is in a partially open state, theone or more damper blades are positioned such that the one or moredamper holes are in a partially open state; and when the manuallyadjustable intake damper is in a fully open state, the one or moredamper blades are positioned such that the one or more damper holes arein a closed state.
 14. The method of claim 13, further comprisingproviding an electronic controller in electrical communication with theelectric fan.
 15. The method of claim 14, further comprising providing atemperature sensor in electrical communication with the electroniccontroller, wherein the electronic controller is configured to varyspeed of the electronic fan based on a signal input from the temperaturesensor.
 16. The method of claim 15, wherein the electronic controllervaries speed of the electronic fan according to aproportional-integral-derivative control algorithm.
 17. The method ofclaim 14, wherein the electronic controller is configured to wirelesslycommunicate with a remote user device.
 18. The method of claim 14,wherein the electronic controller comprises a graphical user interface.